Toner adder roll having an abrasive agent additive

Abstract

A toner adder roll according to one example embodiment includes an electrically conductive shaft defining an axis of rotation of the toner adder roll. A foam member is cylindrically disposed about the shaft and forms an outer circumferential surface of the toner adder roll. The foam member is composed of a polymeric open-cell foam material. An abrasive agent is dispersed on the outer circumferential surface of the toner adder roll.

The invention claimed is: 
     
       1. A toner adder roll, comprising:
 an electrically conductive shaft defining an axis of rotation of the toner adder roll; 
 a foam member cylindrically disposed about the shaft and forming an outer circumferential surface of the toner adder roll, the foam member is composed of a polymeric open-cell foam material; and 
 an abrasive agent dispersed on the outer circumferential surface of the toner adder roll. 
 
     
     
       2. The toner adder roll of  claim 1 , wherein the polymeric open-cell foam material is a polyurethane foam material. 
     
     
       3. The toner adder roll of  claim 1 , wherein the abrasive agent includes at least one of silica, alumina, titania, silicon carbide and ceramic. 
     
     
       4. The toner adder roll of  claim 3 , wherein the abrasive agent includes silica. 
     
     
       5. The toner adder roll of  claim 1 , wherein the abrasive agent is dispersed in the polymeric open-cell foam material. 
     
     
       6. The toner adder roll of  claim 1 , wherein the foam member includes a cured coating on the polymeric open-cell foam material and the abrasive agent is dispersed in the cured coating. 
     
     
       7. The toner adder roll of  claim 6 , wherein the abrasive agent is present in the cured coating at between 2.5% and 12.5% by weight of the cured coating. 
     
     
       8. The toner adder roll of  claim 6 , wherein the foam member includes a conductive agent dispersed in the cured coating. 
     
     
       9. The toner adder roll of  claim 1 , wherein the abrasive agent includes an average aggregate particle size of between 1 micron and 20 microns. 
     
     
       10. A toner adder roll, comprising:
 an electrically conductive shaft defining an axis of rotation of the toner adder roll; 
 a foam member cylindrically disposed about the shaft and forming an outer circumferential surface of the toner adder roll, the foam member is composed of a polymeric open-cell foam material and includes a cured coating on the polymeric open-cell foam material; and 
 a conductive agent and an abrasive agent dispersed in the cured coating, 
 wherein the abrasive agent is present in the cured coating at up to 15% by weight of the cured coating and the abrasive agent has an average aggregate particle size of between 2 nm and 100 microns. 
 
     
     
       11. The toner adder roll of  claim 10 , wherein the abrasive agent includes at least one of silica, alumina, titania, silicon carbide and ceramic. 
     
     
       12. The toner adder roll of  claim 11 , wherein the abrasive agent includes silica. 
     
     
       13. The toner adder roll of  claim 10 , wherein the abrasive agent is present in the cured coating at between 2.5% and 12.5% by weight of the cured coating. 
     
     
       14. The toner adder roll of  claim 10 , wherein the abrasive agent includes an average aggregate particle size of between 1 micron and 20 microns. 
     
     
       15. A developer unit for an electrophotographic image forming device, comprising:
 a reservoir for storing toner; 
 a developer roll having an outer circumferential surface; and 
 a toner adder roll having:
 an electrically conductive shaft defining an axis of rotation of the toner adder roll; 
 a foam member cylindrically disposed about the shaft and forming an outer circumferential surface of the toner adder roll, the foam member is composed of a polymeric open-cell foam material, the outer circumferential surface of the toner adder roll forms a nip with the outer circumferential surface of the developer roll and is positioned to supply toner from the reservoir to the outer circumferential surface of the developer roll; and 
 an abrasive agent dispersed on the outer circumferential surface of the toner adder roll. 
 
 
     
     
       16. The developer unit of  claim 15 , wherein the abrasive agent includes at least one of silica, alumina, titania, silicon carbide and ceramic. 
     
     
       17. The developer unit of  claim 15 , wherein the foam member includes a cured coating on the polymeric open-cell foam material and the abrasive agent is dispersed in the cured coating. 
     
     
       18. The developer unit of  claim 17 , wherein the abrasive agent is present in the cured coating at between 2.5% and 12.5% by weight of the cured coating. 
     
     
       19. The developer unit of  claim 17 , wherein the foam member includes a conductive agent dispersed in the cured coating. 
     
     
       20. The developer unit of  claim 15 , wherein the abrasive agent includes an average aggregate particle size of between 1 micron and 20 microns.